Journal of Manufacturing Processes最新文献_第10页

Research on precision machining for ultra-thin structures based on 3D in-situ ice clamping

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-17 DOI: 10.1016/j.jmapro.2024.11.097

Lingqi Zeng , Haibo Liu , Hao Zhang , Lingsheng Han , Kuo Liu , Yongqing Wang

Improving the rigidity of the machining system in the cutting zone of ultra-thin-walled parts is a challenging problem to ensure machining accuracy, and the use of ice support is an effective method. However, ice and workpieces constitute a completely new process system that generates a complex process response under milling forces/thermal loads, which poses a challenge for deformation prediction. We investigate the milling deformation of ultra-thin parts from the perspective of analyzing the geometric nonlinear large deformation problem of plates. The equilibrium equations between internal forces and milling forces/heat in thin plates are established based on Kármán's assumption, and the equations for controlling the machining deformation of thin-walled parts under ice support are established by introducing the Winkler-Pasternak elastic foundation model, which considers the interfacial shear, to characterize the inverse restraining effect of ice on the ultra-thin-walled parts. Among them, the analytical model of milling force/heat under ice support is established separately in this paper as the load input to the deformation control equation. The displacement function in the form of trigonometric series is introduced to establish the stress function expression coordinated with the displacement, and the coefficients to be determined in the stress function are obtained based on the relationship between stress and deformation of the thin film in the midface. The nonlinear relationship between input load and deformation was solved by using the Bubnov-Galyokin method. A finite element model for milling of thin-walled parts under ice support was established, and the validity of the analytical model was verified by combining with milling experiments. The influence laws of cutting parameters, workpiece structural parameters and freezing condition on machining deformation are analyzed by means of analysis and simulation. Milling experiments were conducted on typical thin-walled parts and the uniformity of workpiece thickness after machining was evaluated. This work provides a theoretical basis for the prediction of machining deformation of ultra-thin parts under ice support.

{"title":"Research on precision machining for ultra-thin structures based on 3D in-situ ice clamping","authors":"Lingqi Zeng , Haibo Liu , Hao Zhang , Lingsheng Han , Kuo Liu , Yongqing Wang","doi":"10.1016/j.jmapro.2024.11.097","DOIUrl":"10.1016/j.jmapro.2024.11.097","url":null,"abstract":"<div><div>Improving the rigidity of the machining system in the cutting zone of ultra-thin-walled parts is a challenging problem to ensure machining accuracy, and the use of ice support is an effective method. However, ice and workpieces constitute a completely new process system that generates a complex process response under milling forces/thermal loads, which poses a challenge for deformation prediction. We investigate the milling deformation of ultra-thin parts from the perspective of analyzing the geometric nonlinear large deformation problem of plates. The equilibrium equations between internal forces and milling forces/heat in thin plates are established based on Kármán's assumption, and the equations for controlling the machining deformation of thin-walled parts under ice support are established by introducing the Winkler-Pasternak elastic foundation model, which considers the interfacial shear, to characterize the inverse restraining effect of ice on the ultra-thin-walled parts. Among them, the analytical model of milling force/heat under ice support is established separately in this paper as the load input to the deformation control equation. The displacement function in the form of trigonometric series is introduced to establish the stress function expression coordinated with the displacement, and the coefficients to be determined in the stress function are obtained based on the relationship between stress and deformation of the thin film in the midface. The nonlinear relationship between input load and deformation was solved by using the Bubnov-Galyokin method. A finite element model for milling of thin-walled parts under ice support was established, and the validity of the analytical model was verified by combining with milling experiments. The influence laws of cutting parameters, workpiece structural parameters and freezing condition on machining deformation are analyzed by means of analysis and simulation. Milling experiments were conducted on typical thin-walled parts and the uniformity of workpiece thickness after machining was evaluated. This work provides a theoretical basis for the prediction of machining deformation of ultra-thin parts under ice support.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 904-930"},"PeriodicalIF":6.1,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143137756","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Laser polishing of additive manufactured stainless-steel parts by line focused beam: A response surface method for improving surface finish

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-17 DOI: 10.1016/j.jmapro.2024.12.028

Abhishek Kumar , Harikrishnan Ramadas , Cheruvu Siva Kumar , Ashish Kumar Nath

Laser polishing is a non-contact method in which laser energy is supplied to the surface selectively, causing localized melting and reflow of the material. A study was conducted on laser powder bed fusion (L-PBF) fabricated 15-5 precipitation hardening (PH) stainless steel specimens to examine the effect of the leading laser polishing process factors on the surface finish. A line-focused beam was employed to polish a large area quickly and effectively. A response surface methodology-based design of experiment was used, the regression equations were obtained, and various surface texture indicators were investigated to understand better the process mechanisms, further supported by a comprehensive microstructure analysis and microhardness test. The results showed a 60 % improvement in surface finish from an initial overall sample area Sa (leveled) of 14.1 μm to 5.57 μm. Gaussian and Robust Gaussian filter with a standard 0.8 mm cutoff was used to extract waviness and roughness. There was a dominance of form error and waviness at higher laser energy densities; thus, it can be shown that shallow surface melting (SSM) predominates at low laser energy densities, while surface over melt (SOM) dominates at higher laser energy densities. The minimum Ra value was obtained as 1.26 μm in the direction of the laser scan direction and 0.68 μm across the laser scan direction. The microhardness of the polished sample increased slightly compared to the base material. Microstructural examination showed no noticeable phase changes throughout the low-energy density laser polishing. At high energy density, the electron backscatter diffraction (EBSD) phase map revealed a gradient microstructure with the austenite content high at the bottom part of the solidified melt pool. Multi-objective desirability function-based optimization was done for minimum Sa (leveled) surface with minimum form error Sa (form). The confirmatory experiments validated the results within 13 % to 20 % error variation.

{"title":"Laser polishing of additive manufactured stainless-steel parts by line focused beam: A response surface method for improving surface finish","authors":"Abhishek Kumar , Harikrishnan Ramadas , Cheruvu Siva Kumar , Ashish Kumar Nath","doi":"10.1016/j.jmapro.2024.12.028","DOIUrl":"10.1016/j.jmapro.2024.12.028","url":null,"abstract":"<div><div>Laser polishing is a non-contact method in which laser energy is supplied to the surface selectively, causing localized melting and reflow of the material. A study was conducted on laser powder bed fusion (L-PBF) fabricated 15-5 precipitation hardening (PH) stainless steel specimens to examine the effect of the leading laser polishing process factors on the surface finish. A line-focused beam was employed to polish a large area quickly and effectively. A response surface methodology-based design of experiment was used, the regression equations were obtained, and various surface texture indicators were investigated to understand better the process mechanisms, further supported by a comprehensive microstructure analysis and microhardness test. The results showed a 60 % improvement in surface finish from an initial overall sample area Sa (leveled) of 14.1 μm to 5.57 μm. Gaussian and Robust Gaussian filter with a standard 0.8 mm cutoff was used to extract waviness and roughness. There was a dominance of form error and waviness at higher laser energy densities; thus, it can be shown that shallow surface melting (SSM) predominates at low laser energy densities, while surface over melt (SOM) dominates at higher laser energy densities. The minimum Ra value was obtained as 1.26 μm in the direction of the laser scan direction and 0.68 μm across the laser scan direction. The microhardness of the polished sample increased slightly compared to the base material. Microstructural examination showed no noticeable phase changes throughout the low-energy density laser polishing. At high energy density, the electron backscatter diffraction (EBSD) phase map revealed a gradient microstructure with the austenite content high at the bottom part of the solidified melt pool. Multi-objective desirability function-based optimization was done for minimum Sa (leveled) surface with minimum form error Sa (form). The confirmatory experiments validated the results within 13 % to 20 % error variation.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 1310-1328"},"PeriodicalIF":6.1,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143137789","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

The mechanism of bright and dark strip visual defects on side milling surfaces induced by loss-cutting

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-17 DOI: 10.1016/j.jmapro.2024.12.013

Dun Lyu, Xiao Xie, Peisheng Lyu, Hui Liu

With the advancement of machining technology, surface visual defects have emerged as a new aspect of surface quality concerns, alongside geometric features and physical-mechanical properties. However, the mechanism behind these visual defects remains unclear. Focusing on bright and dark stripes which is a typical visual defect observed in the side milling process of 3C workpieces, the paper investigates its causes, manifestations, and criteria. Initially, the loss-cutting is identified through analysis of surface profiles during vibration between the workpiece and cutting tool. Subsequent discussion investigates the impact of loss-cutting on surface markings. Furthermore, the study examines surface visual characteristics affected by loss-cutting, utilizing insights into human eye perception. Analysis of causes and manifestations of visual defects in bright and dark stripes follows. Criteria related to working conditions, including spindle speed, feed rate, cutting tool tooth count, and vibration frequency, are then proposed. Finally, experimental validation is conducted. This research bridges gaps in understanding the mechanism and assessment methods of visual defects in surface quality systems, laying groundwork for tracing and controlling such defects.

{"title":"The mechanism of bright and dark strip visual defects on side milling surfaces induced by loss-cutting","authors":"Dun Lyu, Xiao Xie, Peisheng Lyu, Hui Liu","doi":"10.1016/j.jmapro.2024.12.013","DOIUrl":"10.1016/j.jmapro.2024.12.013","url":null,"abstract":"<div><div>With the advancement of machining technology, surface visual defects have emerged as a new aspect of surface quality concerns, alongside geometric features and physical-mechanical properties. However, the mechanism behind these visual defects remains unclear. Focusing on bright and dark stripes which is a typical visual defect observed in the side milling process of 3C workpieces, the paper investigates its causes, manifestations, and criteria. Initially, the loss-cutting is identified through analysis of surface profiles during vibration between the workpiece and cutting tool. Subsequent discussion investigates the impact of loss-cutting on surface markings. Furthermore, the study examines surface visual characteristics affected by loss-cutting, utilizing insights into human eye perception. Analysis of causes and manifestations of visual defects in bright and dark stripes follows. Criteria related to working conditions, including spindle speed, feed rate, cutting tool tooth count, and vibration frequency, are then proposed. Finally, experimental validation is conducted. This research bridges gaps in understanding the mechanism and assessment methods of visual defects in surface quality systems, laying groundwork for tracing and controlling such defects.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 1111-1125"},"PeriodicalIF":6.1,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143138182","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

An improved machining temperature prediction model for aerospace alloys: Effect of cutting edge radius and tool wear

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-17 DOI: 10.1016/j.jmapro.2024.11.092

Jonathan Theraroz , Oguzhan Tuysuz , Julius Schoop

Temperature rise during machining impacts the workpiece material properties, residual stresses, surface and sub-surface quality. Experimental, numerical, and analytical methods have been used to predict the temperature fields in the tool, workpiece and chip. Each approach has its limitations: experimental techniques are cumbersome with expensive equipment, and numerical modeling is computationally inefficient. Existing analytical models only consider the effect of wear while ignoring the edge radius, though the latter changes with the flank wear in practice. To address this limitation, this article proposes an improved analytical temperature prediction model for orthogonal machining by introducing discrete linear heat sources on the edge radius of the cutting edge. The model describes the machining deformation zones by moving or stationary heat sources and models the adiabatic surfaces by imaginary heat sources. The heat partition is calculated to describe the amount of temperature transferred from a heat source to a given body. A global coordinate system is introduced to facilitate the integration of the edge radius in the temperature model, and variation in the direction of the heat source velocity. Temperature predictions of the developed model were experimentally verified using an inverse method based on XRD residual stress measurements. The results of the analysis show that the proposed model is reasonably accurate and most importantly computationally efficient alternative to tedious experimental measurements or more complicated finite element approaches.

{"title":"An improved machining temperature prediction model for aerospace alloys: Effect of cutting edge radius and tool wear","authors":"Jonathan Theraroz , Oguzhan Tuysuz , Julius Schoop","doi":"10.1016/j.jmapro.2024.11.092","DOIUrl":"10.1016/j.jmapro.2024.11.092","url":null,"abstract":"<div><div>Temperature rise during machining impacts the workpiece material properties, residual stresses, surface and sub-surface quality. Experimental, numerical, and analytical methods have been used to predict the temperature fields in the tool, workpiece and chip. Each approach has its limitations: experimental techniques are cumbersome with expensive equipment, and numerical modeling is computationally inefficient. Existing analytical models only consider the effect of wear while ignoring the edge radius, though the latter changes with the flank wear in practice. To address this limitation, this article proposes an improved analytical temperature prediction model for orthogonal machining by introducing discrete linear heat sources on the edge radius of the cutting edge. The model describes the machining deformation zones by moving or stationary heat sources and models the adiabatic surfaces by imaginary heat sources. The heat partition is calculated to describe the amount of temperature transferred from a heat source to a given body. A global coordinate system is introduced to facilitate the integration of the edge radius in the temperature model, and variation in the direction of the heat source velocity. Temperature predictions of the developed model were experimentally verified using an inverse method based on XRD residual stress measurements. The results of the analysis show that the proposed model is reasonably accurate and most importantly computationally efficient alternative to tedious experimental measurements or more complicated finite element approaches.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 1100-1110"},"PeriodicalIF":6.1,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143138191","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Sustainable machining of aluminum MMCs: The role of biomimetic textured cutting tools in cryogenic conditions

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-17 DOI: 10.1016/j.jmapro.2024.11.057

Nageswaran Tamil Alagan , Nikhil Teja Sajja , Pavel Zeman , Tomas Primus , Kalle Falk , Samuel A. Awe

This study evaluated the feasibility of laser-textured biomimetic designs for cutting tools to investigate the effects of laser-textured tools combined with cryogenic cooling using liquid nitrogen (LN₂) on the tool-chip interface, built-up edge (BUE) formation, and friction during Al-MMC machining. This study involved selecting a biomimetic design, converting it into a textured cutting tool, evaluating the coefficient of friction (CoF) and cutting forces on the textured surface under dry conditions, and using cryogenic LN₂ as a coolant with the textured tool. Femtosecond lasers were used to precisely create biomimetic surfaces near the rake face edge without compromising tool integrity. The pin-on-disc method revealed no significant CoF difference between plain and textured tools or among textured tools within the determinate pin load impact. Dry machining tests showed a higher CoF than the pin-on-disc method owing to strong workpiece material adhesion. Cutting force analysis under dry and textured conditions showed negligible effects on aggregate force components, although textured tools had a higher feed force than untextured ones. Cryogenic cooling with plain tools reduced BUE height, TCC_length, and TCCarea compared to dry conditions. Textured tools in dry conditions increased BUE height and acted as chip breakers, reducing TCC_length and TCCarea compared to dry plain tools. Most textured tools with cryogenic cooling reduced the BUE height, TCC_length, and TCC_area compared to their dry-textured counterparts. The findings suggest that combining biomimetic textured cutting tools with cryogenic machining is a promising approach for sustainable manufacturing of Al-MMC's.

{"title":"Sustainable machining of aluminum MMCs: The role of biomimetic textured cutting tools in cryogenic conditions","authors":"Nageswaran Tamil Alagan , Nikhil Teja Sajja , Pavel Zeman , Tomas Primus , Kalle Falk , Samuel A. Awe","doi":"10.1016/j.jmapro.2024.11.057","DOIUrl":"10.1016/j.jmapro.2024.11.057","url":null,"abstract":"<div><div>This study evaluated the feasibility of laser-textured biomimetic designs for cutting tools to investigate the effects of laser-textured tools combined with cryogenic cooling using liquid nitrogen (LN<sub>2</sub>) on the tool-chip interface, built-up edge (BUE) formation, and friction during Al-MMC machining. This study involved selecting a biomimetic design, converting it into a textured cutting tool, evaluating the coefficient of friction (CoF) and cutting forces on the textured surface under dry conditions, and using cryogenic LN<sub>2</sub> as a coolant with the textured tool. Femtosecond lasers were used to precisely create biomimetic surfaces near the rake face edge without compromising tool integrity. The pin-on-disc method revealed no significant CoF difference between plain and textured tools or among textured tools within the determinate pin load impact. Dry machining tests showed a higher CoF than the pin-on-disc method owing to strong workpiece material adhesion. Cutting force analysis under dry and textured conditions showed negligible effects on aggregate force components, although textured tools had a higher feed force than untextured ones. Cryogenic cooling with plain tools reduced BUE height, TCC<sub>length</sub>, and TCCarea compared to dry conditions. Textured tools in dry conditions increased BUE height and acted as chip breakers, reducing TCC<sub>length</sub> and TCCarea compared to dry plain tools. Most textured tools with cryogenic cooling reduced the BUE height, TCC<sub>length</sub>, and TCC<sub>area</sub> compared to their dry-textured counterparts. The findings suggest that combining biomimetic textured cutting tools with cryogenic machining is a promising approach for sustainable manufacturing of Al-MMC's.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 1005-1024"},"PeriodicalIF":6.1,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143138714","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Sustainable multiphase jet polishing of additively manufactured heat pipes utilizing recycled glass chips

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-17 DOI: 10.1016/j.jmapro.2024.11.090

Junyuan Feng , Zhenyu Zhang , Hongxiu Zhou , Cheng Fan , Feng Zhao , Yang Gu , Fanning Meng , Chunjing Shi , Shiqiang Yu

Each year, a huge amount of waste glass chips is produced by machining, which is not recycled and has been treated as waste, resulting in the wasting of resources. However, the pristine physical properties of these micro-sized chips show great potential to be recycled as abrasives in jet polishing. In this work, machined glass chips were recycled and directly used as the abrasives in multiphase jet (MPJ) and abrasive water jet (AWJ) polishing for aluminum heat pipes of additive manufacturing with complex structures. Polishing performance of the recycled abrasives from waste glass was compared with those of commercial quartz abrasives with mesh sizes of 600, 800, 1000, 1200, and 3000. The results show that the recycled abrasives of glass chips have comparable performance to the commercial abrasives with mesh size of 1000. Computational fluid dynamic simulations were conducted on the two jet polishing to elucidate the fundamental material removal mechanisms. It is found that a higher drag force in the AWJ polishing could lead to uniform material removal and induce four times higher for material removal rate (MRR). The cost of setup, water and energy consumptions of MPJ polishing are only one tenth those of AWJ polishing. Energy dispersive spectroscopy reveals that there is no element contamination on the polished surface. This work proposes a novel approach of MPJ polishing for components produced by additive manufacturing with complicated structures. These findings provide new insights for the recycling use of waste chips generated in manufacturing, and suggest new solutions for saving energy and resources, as well as for clean and green production.

{"title":"Sustainable multiphase jet polishing of additively manufactured heat pipes utilizing recycled glass chips","authors":"Junyuan Feng , Zhenyu Zhang , Hongxiu Zhou , Cheng Fan , Feng Zhao , Yang Gu , Fanning Meng , Chunjing Shi , Shiqiang Yu","doi":"10.1016/j.jmapro.2024.11.090","DOIUrl":"10.1016/j.jmapro.2024.11.090","url":null,"abstract":"<div><div>Each year, a huge amount of waste glass chips is produced by machining, which is not recycled and has been treated as waste, resulting in the wasting of resources. However, the pristine physical properties of these micro-sized chips show great potential to be recycled as abrasives in jet polishing. In this work, machined glass chips were recycled and directly used as the abrasives in multiphase jet (MPJ) and abrasive water jet (AWJ) polishing for aluminum heat pipes of additive manufacturing with complex structures. Polishing performance of the recycled abrasives from waste glass was compared with those of commercial quartz abrasives with mesh sizes of 600, 800, 1000, 1200, and 3000. The results show that the recycled abrasives of glass chips have comparable performance to the commercial abrasives with mesh size of 1000. Computational fluid dynamic simulations were conducted on the two jet polishing to elucidate the fundamental material removal mechanisms. It is found that a higher drag force in the AWJ polishing could lead to uniform material removal and induce four times higher for material removal rate (MRR). The cost of setup, water and energy consumptions of MPJ polishing are only one tenth those of AWJ polishing. Energy dispersive spectroscopy reveals that there is no element contamination on the polished surface. This work proposes a novel approach of MPJ polishing for components produced by additive manufacturing with complicated structures. These findings provide new insights for the recycling use of waste chips generated in manufacturing, and suggest new solutions for saving energy and resources, as well as for clean and green production.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 754-768"},"PeriodicalIF":6.1,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143137783","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Fabrication of slow-wave structure by picosecond laser hybridizing with micro-milling

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-17 DOI: 10.1016/j.jmapro.2024.12.008

Xiuqing Hao , Yafang Wan , Wenhao Xu , Jianping Wang , Chengfeng Wei , Zhiwen Hu , Huangcheng Zhu , Luming Zhang , Liang Li , Ning He , Guoqiang Guo

The primary component of traveling-wave tube (TWT) is the slow-wave structure (SWS), which is distinguished by characteristics including a high aspect ratio (HAR), long periodicity, and an incredibly smooth surface. This structure is difficult to process and imposes higher requirements on microfabrication. Therefore, the study proposes a picosecond laser and micro-milling hybridizing processing technology (PLMM) for the processing of SWS. In this method, the picosecond laser was used for rough machining to the initial shaping of the SWS on oxygen-free copper (TU1). Subsequently, micro-milling was employed for the final shaping of SWS. The picosecond laser removes a substantial amount of TU1 and improve the machinability of the TU1. This reduces tool wear in subsequent micro-milling and improves the surface quality of SWS. This study research on the influence of picosecond laser parameters on the TU1 microgroove three-dimensional (3D) dimensions, surface morphology, and the machinability of TU1 material. Subsequently, a comparative experiment between PLMM and traditional micro-milling technology (MM) was carried out. Compared to MM, PLMM improves the surface quality of microgrooves. The chip accumulation at the bottom has been reduced and the average reduction in bottom surface roughness is 46.1 %. Additionally, PLMM reduces tool wear, enhancing tool life. This validates the superiority of PLMM. Finally, a 79-cycle SWS sample was successfully fabricated by PLMM with a width of 0.1 mm and an aspect ratio of 2.8. This research provides a promising direction for the machining of structures characterized by high aspect ratio, long periodicity, and incredibly smooth surface.

{"title":"Fabrication of slow-wave structure by picosecond laser hybridizing with micro-milling","authors":"Xiuqing Hao , Yafang Wan , Wenhao Xu , Jianping Wang , Chengfeng Wei , Zhiwen Hu , Huangcheng Zhu , Luming Zhang , Liang Li , Ning He , Guoqiang Guo","doi":"10.1016/j.jmapro.2024.12.008","DOIUrl":"10.1016/j.jmapro.2024.12.008","url":null,"abstract":"<div><div>The primary component of traveling-wave tube (TWT) is the slow-wave structure (SWS), which is distinguished by characteristics including a high aspect ratio (HAR), long periodicity, and an incredibly smooth surface. This structure is difficult to process and imposes higher requirements on microfabrication. Therefore, the study proposes a picosecond laser and micro-milling hybridizing processing technology (PLMM) for the processing of SWS. In this method, the picosecond laser was used for rough machining to the initial shaping of the SWS on oxygen-free copper (TU1). Subsequently, micro-milling was employed for the final shaping of SWS. The picosecond laser removes a substantial amount of TU1 and improve the machinability of the TU1. This reduces tool wear in subsequent micro-milling and improves the surface quality of SWS. This study research on the influence of picosecond laser parameters on the TU1 microgroove three-dimensional (3D) dimensions, surface morphology, and the machinability of TU1 material. Subsequently, a comparative experiment between PLMM and traditional micro-milling technology (MM) was carried out. Compared to MM, PLMM improves the surface quality of microgrooves. The chip accumulation at the bottom has been reduced and the average reduction in bottom surface roughness is 46.1 %. Additionally, PLMM reduces tool wear, enhancing tool life. This validates the superiority of PLMM. Finally, a 79-cycle SWS sample was successfully fabricated by PLMM with a width of 0.1 mm and an aspect ratio of 2.8. This research provides a promising direction for the machining of structures characterized by high aspect ratio, long periodicity, and incredibly smooth surface.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 1262-1276"},"PeriodicalIF":6.1,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143138184","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

A novel multi-stage pressuring strategy to fabricate sound high‑carbon steel joints in rotary friction welding

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-17 DOI: 10.1016/j.jmapro.2024.11.101

Huihong Liu , Kailiang Chen , Zexi Wu , Yongbing Li , Morisada Yoshiaki , Hidetoshi Fujii

Rotary friction welding (RFW) was employed to join high‑carbon steel SKH51 rods. To mitigate the risk of brittle martensitic transformation at the weld interface, high friction pressure and low rotation speed were used to achieve a welding temperature below the A₁ point. However, the welding temperature exhibited an inherent inhomogeneity across the weld interface, leading to unbonded areas formed at the interface center due to the insufficient heat input. A novel multi-stage pressuring strategy was therefore proposed, wherein the friction pressure was intentionally adjusted at different stages to regulate the pressuring and heat generation behaviors at both the interface center and periphery. A homogeneous temperature distribution below the A₁ point and complete interfacial bonding were successfully achieved across the entire weld interface, enabling the multi-stage RFW SKH51 joint to exhibit exceptional tensile properties comparable to those of the base material.

{"title":"A novel multi-stage pressuring strategy to fabricate sound high‑carbon steel joints in rotary friction welding","authors":"Huihong Liu , Kailiang Chen , Zexi Wu , Yongbing Li , Morisada Yoshiaki , Hidetoshi Fujii","doi":"10.1016/j.jmapro.2024.11.101","DOIUrl":"10.1016/j.jmapro.2024.11.101","url":null,"abstract":"<div><div>Rotary friction welding (RFW) was employed to join high‑carbon steel SKH51 rods. To mitigate the risk of brittle martensitic transformation at the weld interface, high friction pressure and low rotation speed were used to achieve a welding temperature below the <em>A</em><sub>1</sub> point. However, the welding temperature exhibited an inherent inhomogeneity across the weld interface, leading to unbonded areas formed at the interface center due to the insufficient heat input. A novel multi-stage pressuring strategy was therefore proposed, wherein the friction pressure was intentionally adjusted at different stages to regulate the pressuring and heat generation behaviors at both the interface center and periphery. A homogeneous temperature distribution below the <em>A</em><sub>1</sub> point and complete interfacial bonding were successfully achieved across the entire weld interface, enabling the multi-stage RFW SKH51 joint to exhibit exceptional tensile properties comparable to those of the base material.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 957-968"},"PeriodicalIF":6.1,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143137758","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Healing internal cracks of C/C-SiC composite with AgCu alloy for improving C/C-SiC/Ti60 joint performance: Cu-assisted Ag transport in polycrystalline SiC

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-17 DOI: 10.1016/j.jmapro.2024.12.023

Kehan Zhao , Xingyi Li , Duo Liu , Tianliang Xiao , Xiaoguo Song

In this work, a strategy for rapidly healing internal cracks of C/C-SiC composite was developed. Long cracks were effectively healed following treating the composite with AgCu alloy for only 20 min. The healing mechanism was investigated, and the integrity of these healed cracks after reheating was assessed. Additionally, the impacts of crack healing on the C/C-SiC/Ti60 joints were explored. Introducing Cu into Ag dramatically increased the diffusion rate of Ag in SiC by several orders of magnitude, thereby facilitating rapid mass transfer into SiC. Based on this, internal cracks of C/C-SiC composite were healed with AgCu alloy above 1500 °C. The healing agent rapidly migrating within the composite preferentially filled the cracks and generated shrinkage stress upon cooling, collectively contributing to crack closure. The migration of SiC induced by the dissolution-precipitation reaction enhanced the effect of Rayleigh instability and further healed these cracks. The healed cracks remained intact after reheating below 1300 °C and subsequent cooling, ensuring their integrity following brazing. The crack healing resulted in a 108 % improvement in the performance of C/C-SiC/Ti60 joints, attributed to the increased fracture resistance of the joints' weak region. This work was of great significance in repairing ceramic-matrix composite.

{"title":"Healing internal cracks of C/C-SiC composite with AgCu alloy for improving C/C-SiC/Ti60 joint performance: Cu-assisted Ag transport in polycrystalline SiC","authors":"Kehan Zhao , Xingyi Li , Duo Liu , Tianliang Xiao , Xiaoguo Song","doi":"10.1016/j.jmapro.2024.12.023","DOIUrl":"10.1016/j.jmapro.2024.12.023","url":null,"abstract":"<div><div>In this work, a strategy for rapidly healing internal cracks of C/C-SiC composite was developed. Long cracks were effectively healed following treating the composite with AgCu alloy for only 20 min. The healing mechanism was investigated, and the integrity of these healed cracks after reheating was assessed. Additionally, the impacts of crack healing on the C/C-SiC/Ti60 joints were explored. Introducing Cu into Ag dramatically increased the diffusion rate of Ag in SiC by several orders of magnitude, thereby facilitating rapid mass transfer into SiC. Based on this, internal cracks of C/C-SiC composite were healed with AgCu alloy above 1500 °C. The healing agent rapidly migrating within the composite preferentially filled the cracks and generated shrinkage stress upon cooling, collectively contributing to crack closure. The migration of SiC induced by the dissolution-precipitation reaction enhanced the effect of Rayleigh instability and further healed these cracks. The healed cracks remained intact after reheating below 1300 °C and subsequent cooling, ensuring their integrity following brazing. The crack healing resulted in a 108 % improvement in the performance of C/C-SiC/Ti60 joints, attributed to the increased fracture resistance of the joints' weak region. This work was of great significance in repairing ceramic-matrix composite.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 1249-1261"},"PeriodicalIF":6.1,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143138183","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Bilateral submerged abrasive waterjet peening improved high-temperature fatigue strength of titanium alloy thin-walled simplified blades

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-17 DOI: 10.1016/j.jmapro.2024.12.005

Yu-Xin Chi , Shu-Lei Yao , Hua-Yi Cheng , Xian-Hao Zhu , Jia-Wei Liu , Chang-Li Liu , Ning Wang , Cheng-Cheng Zhang , Xian-Cheng Zhang

Waterjet peening has exhibited excellent performance in improving the surface integrity and fatigue life of metal components. This paper proposes a novel and efficient thin-walled simplified-blade-surface full-coverage strengthening method, namely the bilateral submerged abrasive waterjet peening process (BSA-WJP), to improve the surface integrity and fatigue strength of simplified aeroengine blades. First, the surface integrity of simplified titanium alloy TA19 blades treated with BSA-WJP at different abrasive flow rates (100, 175, and 250 g/min) was investigated. The results revealed that the lowest surface roughness value of Ra = 0.329 μm was obtained. Compressive residual stress (CRS) layers of 111–128 μm with a maximum CRS of 738 MPa were introduced to the simplified blade surface. Plastic deformation layers of 15–32 μm were formed on the simplified blade surface after BSA-WJP treatment. The microstructure of the BSA-WJP-treated simplified blade was further examined using transmission electron microscopy. It was found that ultrafine grains with an average size of 107 nm and dense dislocations were induced on the topmost surface and subsurface. Finally, the high-cycle vibration fatigue performance of the simplified TA19 blade at 450 °C was verified. The result revealed that a 13.6 % increase in the high-temperature fatigue limit of the simplified TA19 blade was achieved after BSA-WJP treatment. The fracture morphology revealed that the considerable CRS, grain refinement layer, and optimized surface morphology played significant roles in inhibiting the initiation and propagation of cracks. This study provides an effective method for improving the fatigue strength of titanium alloy thin-walled blades and has promising engineering application prospects.

{"title":"Bilateral submerged abrasive waterjet peening improved high-temperature fatigue strength of titanium alloy thin-walled simplified blades","authors":"Yu-Xin Chi , Shu-Lei Yao , Hua-Yi Cheng , Xian-Hao Zhu , Jia-Wei Liu , Chang-Li Liu , Ning Wang , Cheng-Cheng Zhang , Xian-Cheng Zhang","doi":"10.1016/j.jmapro.2024.12.005","DOIUrl":"10.1016/j.jmapro.2024.12.005","url":null,"abstract":"<div><div>Waterjet peening has exhibited excellent performance in improving the surface integrity and fatigue life of metal components. This paper proposes a novel and efficient thin-walled simplified-blade-surface full-coverage strengthening method, namely the bilateral submerged abrasive waterjet peening process (BSA-WJP), to improve the surface integrity and fatigue strength of simplified aeroengine blades. First, the surface integrity of simplified titanium alloy TA19 blades treated with BSA-WJP at different abrasive flow rates (100, 175, and 250 g/min) was investigated. The results revealed that the lowest surface roughness value of Ra = 0.329 μm was obtained. Compressive residual stress (CRS) layers of 111–128 μm with a maximum CRS of 738 MPa were introduced to the simplified blade surface. Plastic deformation layers of 15–32 μm were formed on the simplified blade surface after BSA-WJP treatment. The microstructure of the BSA-WJP-treated simplified blade was further examined using transmission electron microscopy. It was found that ultrafine grains with an average size of 107 nm and dense dislocations were induced on the topmost surface and subsurface. Finally, the high-cycle vibration fatigue performance of the simplified TA19 blade at 450 °C was verified. The result revealed that a 13.6 % increase in the high-temperature fatigue limit of the simplified TA19 blade was achieved after BSA-WJP treatment. The fracture morphology revealed that the considerable CRS, grain refinement layer, and optimized surface morphology played significant roles in inhibiting the initiation and propagation of cracks. This study provides an effective method for improving the fatigue strength of titanium alloy thin-walled blades and has promising engineering application prospects.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 992-1004"},"PeriodicalIF":6.1,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143137762","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0